Toy projectile and method of making

ABSTRACT

A toy projectile and method of making the toy projectile is provided herein. The toy projectile having: an elongated dart body secured to a tip assembly, the tip assembly comprising: a tip insert secured to a forward end of the elongated dart body and a tip secured to the tip insert, wherein the tip comprises a styrene ethylene butylene styrene copolymer (SEBS rubber) tip.

BACKGROUND

Various embodiments of the present invention relate to a toy projectileor dart and a method of making the toy projectile or dart.

Darts or toy projectiles have been used in toy guns or other toys toprovide an enhanced play factor to the toy guns or toys. As with any toyprojectile it is desirable to provide the same with a blunt soft end aswell as certain characteristics that allow for durability and continueduse.

Accordingly, it is desirable to provide a toy dart or toy projectilethat is easy to manufacture and have robust characteristics as well asproviding for the aforementioned safety factures.

SUMMARY OF THE INVENTION

In one embodiment, a toy projectile is provided, the toy projectilehaving: an elongated dart body secured to a tip assembly, the tipassembly comprising: a tip insert secured to a forward end of theelongated dart body and a tip secured to the tip insert, wherein the tipcomprises a styrene ethylene butylene styrene copolymer (SEBS rubber)tip.

In another embodiment, a toy projectile is provided, the toy projectilehaving: an elongated dart body; a tip assembly, secured to the forwardend of the elongated dart body, the tip assembly comprising: a tipinsert and a tip portion insert molded thereto, the tip insert having aplurality of annular features extending from an exterior surface of thetip insert, wherein at least one of the plurality of annular features iscovered by the tip portion when it is insert molded onto the tip insertand wherein at least one other of the plurality of annular features isonly covered by a forward portion of the elongated dart body when it issecured to tip assembly.

In yet another embodiment, a method of securing a SEBS rubber tip to anextruded dart body is provided. The method including the steps of:forming a tip assembly by inserting a tip insert into a die of aninjection molding machine, wherein the tip insert has a central openingextending therethrough and a plurality of features extending from anexterior surface of the tip insert; insert molding a SEBS rubbermaterial wherein the die of the injection molding machine is configuredto allow a portion of the SEBS rubber material to extend into a portionof the central opening and cover some of the plurality of featuresextending from the exterior surface of the tip insert; removing the tipassembly from the injection molding machine; and securing a forward endof an extruded dart body to at least one of the plurality of features ofthe tip insert that is not covered by the SEBS rubber material.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a view of a dart or projectile in accordance with an exemplaryembodiment of the present invention;

FIG. 2A is an enlarged portion of FIG. 2;

FIG. 2B is a cross-sectional view of the dart or projectile along thelines 2A-2A of FIG. 1;

FIGS. 3A and 3B are front and rear perspective views of the dart orprojectile illustrated in FIG. 1 in accordance with an exemplaryembodiment of the present invention;

FIGS. 4 and 5 are side views of the dart or projectile in accordancewith an exemplary embodiment of the present invention;

FIG. 4A is a view along lines 4A-4A of FIG. 4 or a rear view of the dartor projectile of FIG. 1 in accordance with an exemplary embodiment ofthe present invention;

FIG. 4B is a view along lines 4B-4B of FIG. 4 or a front view of thedart or projectile of FIG. 1 in accordance with an exemplary embodimentof the present invention;

FIG. 6 is a view of a tip assembly constructed in accordance with onenon-limiting exemplary embodiment of the present invention;

FIG. 7 is a cross-sectional view of an insert constructed in accordancewith one non-limiting exemplary embodiment of the present invention;

FIG. 8 is a cross-sectional view a tip assembly constructed inaccordance with one non-limiting exemplary embodiment of the presentinvention;

FIG. 9 is a flowchart illustrating a method or process for forming adart or projectile in accordance with one non-limiting exemplaryembodiment of the present invention;

FIGS. 10 and 11 illustrating an apparatus for trimming a tail orrearward end of the dart or projectile;

FIG. 12 illustrates an apparatus for securing an extruded dart body to atip assembly;

FIG. 13 illustrates a dart or projectile formed in accordance with analternative exemplary embodiment of the present invention; and

FIGS. 13A-13D portions of the dart or projectile illustrated in FIG. 13.

Although the drawings represent varied embodiments and features of thepresent invention, the drawings are not necessarily to scale and certainfeatures may be exaggerated in order to illustrate and explain exemplaryembodiments the present invention. The exemplification set forth hereinillustrates several aspects of the invention, in one form, and suchexemplification is not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Referring now to the FIGS. and in particular FIGS. 1-5, a dart orprojectile 10 constructed in accordance with an exemplary embodiment ofthe present invention is illustrated. Dart or projectile 10 has anelongated tubular body portion 12 which has a forward end or front end14 and a rearward end 16. Rearward or rear end 16 has an opening 17 thatextends into opening 19 of the elongated tubular body portion 12.Secured to the forward end 14 is a tip assembly 18. Tip assembly 18 hasa tip portion 20 and a tip insert 22. The tip portion 20 is secured to afirst portion of the tip insert 22 and a second portion of the tipinsert is secured to the forward end 14 of the elongated tubular bodyportion 12.

Accordingly, tip insert 22 provides a means for securing the tip 20 tothe forward end 14 of the elongated tubular body portion 12. In oneexemplary embodiment, tip insert 22 is configured to have an inneropening 24 extending therethrough. In addition, an exterior surface 26of the tip insert 22 is configured to have a plurality of features orannular rings 28 extending away from the exterior surface 26 of the tipinsert 22. In one embodiment, the plurality of features or annular rings28 provide securement features to which the tip 20 and the forward end14 are secured thereto. Still further, the plurality of features orannular rings also provide a plurality of grooves 30 located between theannular rings. The features or annular rings 28 as well as the grooves30 located therebetween provide a mechanism for rigidly securing theforward end 14 to the tip assembly 18. In one implementation and as thematerial of forward end 14 is pushed between annular rings 28 and thencooled, an interlock of the tip assembly 18 and the tubular body portion12 is formed.

FIG. 6 illustrates a tip assembly 18 formed in accordance with onenon-limiting exemplary embodiment of the present invention. FIG. 7 is across-sectional view of the tip insert 22 formed in accordance with onenon-limiting exemplary embodiment of the present invention while FIG. 8is a cross-sectional view of the tip insert 22 with the tip 20 securedthereto. As illustrated, the plurality of features or annular rings 28provide securement features to which the tip 20 and the forward end 14are secured thereto. Still further, the plurality of features or annularrings 28 also provide a plurality of grooves 30 located between theannular rings. In accordance with one embodiment, the height or distanceof the annular rings 28 may vary. In addition, a rearward end 32 of thetip insert 22 maybe formed with a flange portion 34 which providesadditional rigidity to the tip insert and/or tip assembly and inparticular to the area that is secured to the forward end 14 of theelongated dart body 12.

In accordance with one non-limiting exemplary embodiment, the tip insert22 is formed from the following material TPR Thermoflex ME1385 via aninjection molding process. Of course, other equivalent materials forforming the tip insert are considered to be within the scope ofexemplary embodiments of the present invention. In one non-limitingexemplary embodiment, the core part or tip insert 22, was shot at a tempof 225° C. and the shot pressure was 65 bar for a cycle time of 40seconds. Of course, other temperatures, times and pressures greater andless than the aforementioned values are considered to be within thescope of various embodiments of the present invention.

In accordance with one non-limiting exemplary embodiment, the tip 20 isformed from a styrene ethylene butylene styrene copolymer (SEBS rubber)or more particularly the following material TPR Thermoflex ME1927 via aninjection molding process. Of course, other equivalent materials forforming the tip are considered to be within the scope of exemplaryembodiments of the present invention. In one non-limiting exemplaryembodiment, the tip part was shot at a temp of 225° C. and the shotpressure was 50 bar for a cycle time of 60 seconds. Of course, othertemperatures, times and pressures greater and less than theaforementioned values are considered to be within the scope of variousembodiments of the present invention.

In accordance with one non-limiting exemplary embodiment, the elongatedtubular body portion 12 is formed from an extrusion process wherein thetubular body portion is formed from a polyethylene which in oneembodiment comprises 60% LDPE and 40% HDPE. Of course, other equivalentmaterials and combinations thereof are considered to be within the scopeof exemplary embodiments of the present invention.

Referring now to FIG. 9 a flowchart 40 illustrating one non-limitingmethod for forming the dart or projectiles 10 is provided. At box 42 atleast one or a plurality of tip inserts 22 are formed by theaforementioned injection molding process. Simultaneously, previously orafterwards at least one or a plurality of elongated tubular dart bodyportion 12 are formed by an extrusion process at step 44. During thisstep or process the tubular body portion 12 is formed from an extrusionmachine wherein an elongated member is extruded from the aforementionedmaterials and once cooled, the extruded member is cut into the desiredlengths for use as tubular body portion 12.

At step 46, the rear end or tail end 16 of the elongated tubular dartbody portion proximate to opening 17 is trimmed to have a curved orrounded surface 48 (see at least FIG. 1). Once trimmed, the elongatedtubular body portion 12 is ready to be secured to the tip assembly 18.In an alternative embodiment step 46 may be eliminated.

At a step 50, the molded tip insert 22 is inserted into an injectionmolding machine wherein the tip portion 20 is insert molded onto aportion of the tip insert 22 as described above and illustrated in theattached FIGS. Once this process is complete, the tip assembly 18 is nowformed.

After conclusion of the process at step 50, the form tip assemblies 18are now secured to the elongated body portions 12 via a heat treatingprocess which occurs at step 52.

Referring now to FIGS. 10 and 11, an apparatus 54 for use in thetrimming step 46 is illustrated. Apparatus 54 has a plunger 56 ontowhich the extruded elongated body 12 is placed and an end portion 58 ofplunger 56 has corresponding rounded ends which form the rounded ends orend 48 of the elongated body portion 12 when plunger 56 is moved towardsa copper plate or other of material 70 which is heated in order tomanipulate or trim the extruded elongated body 12 to have a trimmed endor rounded surface 48.

FIG. 12 illustrates an apparatus 72 for use in step 52 wherein theelongated body 12 with the tip insert inserted into a forward end 14 ofthe elongated body 12 is placed between a pair of rollers 74 whichrotate the same. A heated copper roller assembly or other equivalentmaterial 76 applies heat and pressure to the forward end 14 of theelongated body such that portions of the same are now pushed into thegrooves 30 of tip insert 22 so that the elongated body 12 is now securedto the tip assembly 18 and the dart or projectile 10 is formed.

Referring now to the FIGS. 13-13D an alternative exemplary embodiment ofthe present invention is illustrated. Here the tip insert 22 and the tipportion 20 have alternative configurations. In this embodiment, afterthe insert molding process the tip 20 or material used to form tip 20extends completely through the central opening 24 of the tip insert 22and is received within the central opening of the elongated tubular body12. In addition and in this embodiment, the forward end 14 of theelongated body 12 is formed onto features 28 and groove 30 as well as aportion of tip portion 20. Of course, numerous other configurations areconsidered to be within the scope of exemplary embodiments of thepresent invention and the above embodiments are merely examples ofvarious embodiments of the present invention.

As used herein, the terms “first,” “second,” and the like, herein do notdenote any order, quantity, or importance, but rather are used todistinguish one element from another, and the terms “a” and “an” hereindo not denote a limitation of quantity, but rather denote the presenceof at least one of the referenced item. In addition, it is noted thatthe terms “bottom” and “top” are used herein, unless otherwise noted,merely for convenience of description, and are not limited to any oneposition or spatial orientation.

The modifier “about” used in connection with a quantity is inclusive ofthe stated value and has the meaning dictated by the context (e.g.,includes the degree of error associated with measurement of theparticular quantity).

While the invention has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A toy projectile, comprising: an elongated dartbody secured to a tip assembly, the tip assembly comprising: a tipinsert secured to a forward end of the elongated dart body and a tipsecured to the tip insert, wherein the tip comprises a styrene ethylenebutylene styrene copolymer tip, wherein tip insert has an outer surfaceand a plurality of features extending from the outer surface.
 2. The toyprojectile as in claim 1, wherein tip insert has a central openingextending therethrough.
 3. The toy projectile as in claim 1, wherein tipis insert molded onto the tip insert and portions of the tip extend intothe central opening and cover some of the plurality of featuresextending from the outer surface.
 4. The toy projectile as in claim 3,wherein the forward end of the elongated dart body is thermoformed to atleast one of the plurality of features extending from the outer surfacethat is not covered by a portion of the tip.
 5. The toy projectile as inclaim 4, wherein the elongated dart body has a rearward end opposite theforward end and the rearward end is configured to have a roundedexterior surface.
 6. The toy projectile as in claim 5, wherein theelongated dart body has a central opening extending therethrough.
 7. Thetoy projectile as in claim 6, wherein the central opening of theelongated dart body is in fluid communication with a portion of thecentral opening of the tip insert that is not filled with a portion ofthe tip.
 8. The toy projectile as in claim 1, wherein tip is insertmolded onto the tip insert prior to the disassembly being secured to theelongated dart body.
 9. The toy projectile as in claim 1, wherein theelongated dart body has a rearward end opposite the forward end and arearward end is configured to have a rounded exterior surface.
 10. A toyprojectile, comprising: an elongated dart body; a tip assembly, securedto the forward end of the elongated dart body, the tip assemblycomprising: a tip insert and a tip portion insert molded thereto, thetip insert having a plurality of annular features extending from anexterior surface of the tip insert, wherein at least one of theplurality of annular features is covered by the tip portion when it isinsert molded onto the tip insert and wherein at least one other of theplurality of annular features is only covered by a forward portion ofthe elongated dart body when it is secured to tip assembly.
 11. The toyprojectile as in claim 10, wherein tip insert has a central openingextending therethrough.
 12. The toy projectile as in claim 10, whereinthe elongated dart body is a central opening extending therethrough. 13.The toy projectile as in claim 10, wherein a rearward portion of theelongated dart body is configured to have a rounded end.
 14. The toyprojectile as in claim 10, wherein the forward end of the elongated dartbody is thermoformed into a groove located between least two of theplurality of features extending from the outer surface that are notcovered by a portion of the tip.
 15. The toy projectile as in claim 10,wherein the tip is formed from a styrene ethylene butylene styrenecopolymer.
 16. The toy projectile as in claim 10, wherein the centralopening of the elongated dart body is in fluid communication with aportion of the central opening of the tip insert that is not filled witha portion of the tip.